some quick points:- why are you trying to install it twice?- afaik fat16 is used due to compatibility, although it does have its limitations esp. on capacity. However, it is not a problem in your context... see the above point.- from what I have seen, the 512MB limitation depends on the system/drive... and (that determines) the installation method.- since there are so many different ways and problems, the USB-install scripts were deemed to be removed from the base image (still pending)- for relatively newer systems, using an ext2 partition (at the end of the drive if you plan on using the rest with windows) with extlinux should be fine (w/ usb-hdd system capability I think)- in any case, I have seen DSL on various sized usb's... perhaps searching the forums would be better in this case

EDIT: Anyone feel free to correct/add to these, since most of this is just coming from what I've read over somewhat, and concluded from it

Correct. The scripts in the core DSL are for the smallest of drives, which are still a viable choice. However using various FAT have limitations on size and efficiency. With so many new and much larger pendrives, these in core scripts are often not the best choice. Also consider the many ways to iinstall.

I know that this is a bit off-topic for the people who have BIOS that supports booting directly from USB, but I normally only have access to older machines and so I have to configure for other methods :-

Copied the DSL /KNOPPIX/KNOPPIX and /lost+found files to an ext2 partition on the USB stick.

I use a FAT16 partition (could be FAT32 depending what size you might want to be windows-readable) at the 'start' of the USB stick where settings and so on can be saved.

There is also a SWAP partition.

Add MyDSL extensions to taste

Boot from the 'vanilla' DSL bootfloppy.img (or a DSL CD remastered omitting the KNOPPIX file on floppy-less hardware) with the cheatcode

fromusb

This set-up should be tolerant of a variety of partition configurations.NB it assumes that there is not another KNOPPIX image on the host system that would be found earlier.